Method for preparing calcium sulfonate complexes



3,350,308 Patented Oct. 31, 1967 3,350,308 METHOD FOR PREPARING CALCIUM SULFONATE COMPLEXES Richard L. McMillen, Painesville, Ohio, assignor to The Lnhrizol Corporation, Wicklilfe, Ohio, a corporation of Ohio N0 Drawing. Filed June 17, 1966, Ser. No. 558,287 10 Claims. (Cl. 25233) ABSTRACT OF THE DISCLOSURE Calcium sulfonates with a metal ratio of at least about 10 are prepared by reacting a carbonated calcium sulfonate complex of lower metal ratio with a calcium base in the presence of an aliphatic monohydri-c alcohol and an oil-soluble calcium phenate, and then carbonating to a base number below about 50. The products are superior in filterability and solids content to similar ones prepared without the calcium phenate. They are useful as lubricant additives.

This application is a continuation-in-part of copending application Ser. No. 309,293, filed Sept. 16, 1963, now abandoned.

This invention relates to alkaline earth metal sulfonates containing stoichiometrically large amounts of metal, to methods for their preparation, and to lubricants containing them. More particularly, the invention relates to a method for preparing a substantially neutral, carbonated calcium sulfonate complex having a metal ratio of at least about 10 which comprises preparing and mixing a mass in which, at 50 C., at least 50 percent of the components are in the liquid state, and in which mass the active components consist of:

(A) a carbonated calcium sulfonate complex having a metal ratio of from about 1.1 to about 8.0;

(B) an oil-soluble calcium phenate; the ratio of equivalents of APB being in the range from about 20:1 to about 2:1;

(C) an aliphatic monohydric alcohol having from 1 to about 20 carbon atoms, in an, amount of at least 5 percent by weight of A; and

(D) a calcium base, in an amount such that there is present in the mass a total of at least about 10 equivalents of calcium per equivalent of' A; and then treating the mass with carbon dioxide until the base number thereof is less than about 50 and heating it to drive off substantially all the alcohol and any water present.

It is known in the sulfonate art, as exemplified by Mertes US. Patent 2,501,731, Asseff et a1. U.S. Patent 2,723,234, and McMillen et al. US. Patent 3,027,325, that a normal calcium sulfonate or sulfonic acid can be complexed with substantially more calcium than is equivalent to the sulfonic acid anion. The techniques employed by these patentees involve heating and carbonating a mixture of a sulfonic acid or a calcium sulfonate, a slight stoichiometric excess of a calcium base such as calcium oxide or calcium hydroxide, and a promoting agent such as water, a water-alcohol mixture, a phenol, a nitroalkane, or a similar active hydrogen compound. While the exact composition of the products of these patentees is not known, some researchers believe, on the basis of the Tyndall efiect, that the excess calcium is due to a dispersion or colloidal suspension of calcium carbonate and/or calcium bicarbonate in the normal sulfonate. In any event, such compositions are known to possess a high calcium content which in many instances cannot be explained by known basic salt structures. Such known methods are effective to produce carbonated calcium sulfonate complexes having metal ratios from about 1.1 to a maximum of about 8.0. The term metal ratio as used herein is the ratio of the total equivalents of calcium in the sulfonate complex to the equivalents of sulfonic acid anion therein. It is, thus, a measure of the stoichiometric excess of calcium in a calcium sulfonate complex. For example, a normal sulfonate has a metal ratio of 1.0 and a calcium sulfonate complex which contains twice as much calcium as the normal sulfonate has a metal ratio of 2.0.

It is possible to prepare calcium sulfonates with metal ratios of 10 or above by reacting a lower metal ratio calcium sulfonate with a calcium base in the presence of an alcohol promoter; indeed, this method is now in commercial use. However, diificulties are often encountered in processing sulfonates made by this method. In particular, filtration of the product is often slow and laborious and requires large amounts of filter aid material. Furthermore, the product often contains a relatively high percentage of solids which are undesirable for many applications.

A principal object of the present invention, therefore, is to provide an improved process for the preparation of oil-soluble, substantially neutral calcium sulfonate complexes with metal ratios of at least about 10.

A further object is to provide a convenient process for preparing high metal ratio calcium sulfonate complexes of low solids content.

Other objects will be apparent from the following description.

As used in the present specification and claims, the term substantially neutral refers to sulfonate complexes having a strong base number or acid number less than about 20, as determined by ASTM procedure D974.

The substantially neutral, carbonated calcium sulfonate complexes of this invention find their principal utility as improving agents for liquid lubricants and as starting materials for the preparation of bodied lubricants or greases. Due to their high alkaline reserve, they are particularly efiective in neutralizing acidic materials which are found in internal combustion engine crankcase oils as a result of oxidative decomposition of the oil and/or contamination thereof with acidic blow-by products from the combustion chamber.

COMPONENT A As indicated previously, this component is a carbonated calcium sulfonate complex having a metal ratio of from about 1.1 to about 8.0. These complexes may be repared from oil-soluble calcium sulfonates or sulfonic acids by known methods such as those set forth, for example, in the above-noted patents to Mertes, Asseff et al. and Mc- Millen et al. In the interest of not unduly lengthening the present specification, it is intended that the disclosures of these patentees be considered as forming a part of this application.

The oil-soluble calcium sulfon-ates and/ or sulfonic acids useful as starting materials for the preparation of component A can be of the cyclic or aliphatic type. The cyclic compounds include the monoor poly-nuclear aromatic or cycloaliphatic compounds. The oil-soluble sulfonates can be represented for the most part by the following formulas:

In the above formulas, M is either calcium or hydrogen; T is a cyclic nucleus such as, for example, benzene, naphthalene, anthracene, phenanthrene, diphenylene oxide, thianthrene, phenothioxine, diphenylene sulfide, phenothiazine, diphenyl oxide, diphenyl sulfide, diphenylamine, cy-clohexane, petroleum naphthenes, decahydronaphthalene, cyclopentane, etc.; R is an aliphatic group such as alkyl, alkenyl, alkoxy, alkoxyalkyl, carboall oxy-- alkyl, etc.; x is at least 1, and R T contains a total of at least about 15 carbon atoms. R in Formula II is an aliphatic radical containing at least about 15 carbon atoms and M is either calcium or hydrogen. Examples of types of the R radical are alkyl, alkenyl, alkoxyalkyl, carboalkoxyalkyl, etc. Specific examples of R are petrolatum, saturated and unsaturated paraffin wax, and polyolefins, including polymerized C C C C C etc., olefins containing from about 15 to 7000 or more carbon atoms. The groups T, R, and R in the above formulas can also contain other inorganic or organic substituents in addition to those enumerated above such as, for example, hydroxy, mercapto, halogen, nitro, amino, nitroso, sulfide, disulfide, etc. In Formula I, x, y, z and b are at least 1, and likewise in Formula II, a, b and d are at least 1.

The following are specific examples of oil-soluble sulfonic acids coming within the scope of Formulas I and II above, and it is to be understood that such examples serve also to illustrate the calcium salts of such sulfonic acids. In other words, for every sulfonic acid enumerated it is intended that the corresponding calcium salt thereof is also illustrated. Such sulfonic acids are mahogany sulfonic acids; bright stock sulfonic acids; sulfonic acids derived from lubricating oil fractions having a Saybolt viscosity from about 100 seconds at 100 F. to about 200 seconds at 210 F.; petrolatum sulfonic acids; monoand poly-wax substituted sulfonic and polysulfonic acids of, e.g., naphthalene, phenol, diphenyl ether, naphthalene disulfide, diphenylamine, thiophene, alphachloronaphthalene, etc.; other substituted sulfonic acids such as cetyl chlorobenzene sulfonic acids, cetylphenol mono-sulfide sulfonic acids, cetoxy capriylbenzene sulfonic acids, dicetyl thianthrene disulfonic acids, dilauryl betanaphthyl sulfonic acids, dicapryl nitronaphthalene sulfonic acids,

' and alkaryl sulfonic acids such as dodecyl benzene bottoms sulfonic acids. The latter are acids derived from benzene which has been alkylated with propylene tetramers or isobutene trimers to introduce 1, 2, 3, or more branched-chain C substituents on the benzene ring. Dodecyl benzene bottoms, principally mixtures of monoand di-dodecyl benzenes, are available as lay-products from the manufacture of household detergents. Also included are aliphatic sulfonic acids such as paraffin wax sulfonic acid, unsaturated paraffin wax sulfonic acids, hydroxy-substituted paraffin wax sulfonic acids, hexapropylene sulfonic acids, tetraamylene sulfonic acids, polyisobutene sulfonic acids wherein the polyisobutene contains from 20 to 7000 or more carbon atoms, chlorosubstituted paraffin wax sulfonic acids, nitro-paraffin Wax sulfonic acids, etc.; cycloaliphatic sulfonic acids such as petroleum naphthene sulfonic acids, cetyl cyclopentyl sulfonic acids, lauryl cyclohexyl sulfonic acids, bis-(diisobutyl) cyclohexyl sulfonic acids, monoor poly-wax substituted cyclohexyl sulfonic acids, etc. Additional examples of oil-soluble sulfonic acids and/ or calcium salts thereof which can be used as starting materials for the preparation of component A are disclosed in many US. patents.

With respect to the sulfonic acids or calcium salts thereof, it is intended herein to employ the term petroleum sulfonic acids or calcium petroleum sulfonates to cover all sulfonic acids or the calcium salts thereof derived from petroleum products. A particularly valuable group of petroleum sulfonic acids are the mahogany sulfonic acids (so called because of their reddish-brown color) obtained as a by-product from the manufacture of petroleum white oils by a sulfuric acid process. It is to be understood that the sulfonic acids and calcium salts thereof enumerated above are not all equivalent for the purposes of the present invention because, under certain conditions, some are more effective than others.

The following examples are presented to illustrate specific carbonated calcium sulfonate complexes useful as component A herein. In summary, the preparation of such complexes involves carbonating a mixture of calcium sulfonate and/or sulfonic acids, calcium base, and a promoting agent at 50-250 C. for 0.5-10 hours and then isolating the oil-soluble carbonated calcium sulfonate complex by suitable means, generally filtration or centrifugation. In most cases, it is preferred to car-- bonate the reaction mass before filtration or centrifuga-- tion, since higher metal ratios are obtained when the carbonation is conducted in this manner. Unless otherwise specified, all parts and percentages are by weight. Mineral oil, when used, is a neutral oil having a viscosity of 100-110 Saybolt seconds at 100 F.

Example 1 A normal calcium mahogany sulfonate is prepared by metathesis of a 60% oil solution of sodium mahogany sulfonate (750 parts) with a solution of 67 parts of cal-- cium chloride in 63 parts of water. The reaction mass is heated for 4 hours at -100 C. to effect the conversion of the sodium mahogany sulfonate to calcium mahogany sulfonate. 54 parts of lime is then added and the whole is heated to 150 C. over a period of 5 hours. When the whole has cooled to 40 C., 98 parts of methanol is added and 152 parts of carbon dioxide is introduced over a period of 20 hours at 4243 C. Water and alcohol are then removed by heating the mass to 150 C. The residue in the reaction vessel is diluted with 100 parts of low viscosity mineral oil and filtered for purposes of purification. The purified oil solution of the desired carbonated calcium sulfonate complex shows the following analyses:

Sulfate ash, percent 16.4

Neutralization No. (acidic) 0.6

Metal ratio 2.50

Example 2 880 grams (0.968 mole) of a 57.5% oil solution of thecalcium sulfonate of tridecylbenzene bottoms (the bottoms constitute a mixture of monoand di-tridecyl benzenes), 149 grams of methanol, and 59 grams (1.58 equivalents) of calcium hydroxide are introduced into a reaction vessel and stirred vigorously. The whole is heated to 40-45 C. and carbon dioxide is introduced for 0.5 hour at the rate of 2 cubic feet per hour. The carbonated reaction mixture is then heated to 150 C. to remove alcohol and any water present, and the residue is filtered for purposes of purification. The product, a 61% oil solution of the desired carbonated calcium sulfonate complex, shows the following analyses:

Sulfate ash, percent 16.84 Neutralization No. (acidic) 7.0 Metal ratio 2.42

Example 3 A mixture of 1045 grams (1.0 equivalent) of a 45% oil solution of calcium mahogany sulfonate containing 1% of water, 254 grams (7.0 equivalents) of calcium hydroxide, and 251 grams of methanol is prepared, heated to 40 C., and then treated with carbon dioxide at 4045 C. for 9 hours. The Whole is then heated to 150 C., diluted with 790 grams of mineral oil, and filtered for pur poses of purification. The filtrate, the desired carbonated calcium mahogany sulfonate complex, shows the following analyses:

Sulfate ash, percent 22.2

Neutralization No. (acidic) 0.4

Metal ratio 7.1

Example 4 A mixture of 1045 grams (1.0 equivalent) of a 45% oil solution of mixed calcium mahogany sulfonate and calcium polydodecyl benzene sulfonate containing 1% of water, 259 grams (7.0 equivalents) of calcium hydroxide,

126 grams of methanol, and 790 grams of mineral oil is heated at the reflux temperature for 1 hour and then treated with carbon dioxide for 4.2 hours at 4045 C. The mixture is then heated to 150 C. to remove alcohol and any water present. The residue is filtered to yield the desired carbonated calcium sulfonate complex, which shows the following analyses:

Sulfate ash, percent 21.3

Neutralization No. (acidic) 1.2

Metal ratio 6.9

Example 5 A mixture of 2090 grams (2.0 equivalents) of a 45% oil solution of calcium mahogany sulfonate containing 1% of water, 370 grams (10.0 equivalents) of calcium hydroxide, and 251 grams of methanol is heated at the reflux temperature for 1 hour. It is then cooled to 40 C., whereupon carbon dioxide is bubbled through the whole for 14 hours. The carbonated mixture is then heated to 150 C., held at this temperature for 1 hour, and filtered. The filtrate, the desired carbonated calcium sulfonate complex, shows the following analyses:

Sulfate ash, percent 30.0

Neutralization No. (acidic) 0.9

Metal ratio 5.7

Example 6 A mixture of 74 grams (2.0 equivalents) of calcium hydroxide, 167 grams of water, and 251 grams of isopropanol is heated at the reflux temperature for 1 hour and then treated with 2090 grams of' a 45% oil solution of calcium mahogany sulfonate. Carbon dioxide is then bubbled through the mixture at 4045 C. for 2.2 hours. The isopropanol and water are removed by heating the mixture to 150 C., after which the residue is filtered for purposes of purification. The filtrate, the desired carbonated calcium sulfonate complex, shows the following analyses:

Sulfate ash, percent 12.1

Neutralization No. (basic) 28 Metal ratio 2.0

Example 7 Sulfate ash, percent 12.9

Neutralization No. (acidic) 5.0

Metal ratio 2.0

Example 8 A slurry of 74 grams (2.0 equivalents) of calcium hydroxide in 251 grams of ethanol is heated at the reflux temperature for 1 hour. To this there is added 2090 grams (2.0 equivalents) of a 45 oil solution of calcium 'rnahogany sulfonate containing 1% of water. This mixture is treated with carbon dioxide for 4.5 hours at 4045 C. The resulting product is heated to 150 C., then filtered to yield the purified product. The filtrate, the desired. carbonated calcium sulfonate, shows the following analyses:

Sulfate ash, percent 11.4 Neutralization No. (basic) 0.7 Metal ratio 1.8

Example 9 A solution of 185 grams (5.0 equivalents) of calcium hydroxide in 251 grams of isopropyl alcohol and 167 grams of water is heated under reflux for 1 hour. To this solution there is added 2090 grams (2.0 equivalents) of a 45 oil solution of calcium mahogany sulfonate. The temperature is adjusted to 4045 C. and carbon dioxide is bubbled through the mass for 1.8 hours, at which point the neutralization number is 12.4 (basic). The mixture is then heated to 150 C. and treated for an additional hour at this temperature with carbon dioxide. The whole is diluted with benzene, filtered, and the filtrate concentrated by heating to 150 C./ 30 mm. Hg. The residue, the desired carbonated calcium sulfonate complex, shows the following analyses:

Sulfate ash, percent 12.3

Neutralization No. (acidic) 0,7

Metal ratio 2.0

Example 10 A mixture of 459 grams of phenol, 244 grams of water, and 90.5 grams of calcium hydroxide is stirred at the reflux temperature for 2 hours. Thereafter 1046 grams of a 45% oil solution of calcium mahogany sulfonate is added. The mass is then heated to C., at which temperature a distillate consisting of 244 grams of water and 32 grams of phenol is obtained. Thereafter the dehydrated mixture is blown with carbon dioxide for 3 hours at 120150 C. and an additional 60 grams of distillate is collected, which upon analysis is found to contain 42 grams of phenol. Upon heating the mass further to 200 C./ 20 mm. Hg, 375 grams more of phenol is recovered. The residue in the flask is then filtered to yield the desired carbonated calcium sulfonate complex, which shows the following analyses:

Sulfate ash, percent 18.35

Neutralization No. (basic) 8.07

Metal ratio 3.07

Example 11 1120 grams of a 45% oil solution of calcium mahogany sulfonate, 59 grams of l-nitro-propane, grams of calcium hydroxide, and 830 grams of water are mixed and heated to 100 C. and held there for 1 hour. The temperature is then raised to 150 C. and held at that level for 1 hour. The product is filtered and then blown with carbon dioxide for 2 hours at 150 C. The carbonated filtrate, the desired carbonated calcium sulfonate complex, shows the following analyses:

Sulfate ash, percent 13.15 Neutralization No. (basic) 2.0 Metal ratio 2.36

COMPONENT B This component is an oil-soluble calcium phenate. Principally useful are the calcium phenates of alkylphenols and alkylphenol-aldehyde condensation products, in which phenates the alkyl substituent or substituents contain a total of at least about 6 carbon atoms to impart oil solubility. The term phenol or phenols as used herein are intended to include both monoand polyhydric monoor polynuclear phenols; the term alkyl is intended to embrace both open chain and cyclic alkyl groups. In most instances, the alkylphenol which is converted directly to the calcium phenate or condensed with an aldehyde and converted to the calcium phenate will be a monoalkyl mononuclear phenol in which the alkyl substituent contains from about 3 to about 150 and preferably from about 4 to about 50 carbon atoms. Generally such monoalkyl mononuclear phenol will be devoid of substituents other than the characterizing hydroxyl group and alkyl group or groups, although for some purposes substituent groups such as chloro, bromo, nitro, sulfide,

disulfide, ether, amino, nitroso, etc., may be present in the alkyl substituent and/ or the aromatic nucleus. Thus, for some purposes it is desirable, for example, to employ a calcium phenate of an alkylphenol which has been converted to the corresponding monosulfide or disulfide.- Specific examples of alkylphenols useful for the purposes: of this invention include the following (for each alkylphenol given, it is intended to illustrate the corresponding calcium phenate): o, p-diethylphenol; n-propylphenol, p-isopropylphenol, diisopropylphenol, n-butyl-- phenol, p-tertiary-butylphenol, n-amylphenol, p-tertiaryamylphenol, p cyclopentylphenol, cyclohexylphenol, methylcyclohexylphenol, secondary-hexylphenol, heptylphenol, tertiary-octylphenol, 3,5,5 trimethyl n hexylphenol, ndecylphenol, cetylphenol, oleylphenol, waxalkylated phenol, polyisobutene-substituted phenol in which the polyisobutene substituent contains from about 20 to about 150 or more carbon atoms, etc.; alkylated aryl substituted phenols such as heptyl phenylphenol, isooctyl diphenylphenol, and di-tertiary-amyl naphthylphenol; alkylated polydroxy aromatic compounds such as heptylalizarin, n-octylquinizarin, isododecylhydroquinone, octylcatechol, heptyl pyrogallol, etc.; alkylated monohydroxy naphthalenes such as dihexyl substituted alpha-naphthol and beta-naphthol; alkylated polyhydroxy naphthalenes such as heptyl substituted naphthohydroquinine and naphthoresorcinol; and substituted phenols such as heptyl p-nitrophenol, isododecyl picric acid, pn-octyl ortho-chlorophenol, tertiary-butyl chlorophenol, ortho-heptyl p-aminophenol, octylphenol monosulfide, heptylphenol disulfide, 2:1 molar condensation product of heptylphenol and formaldehyde, 1:1 molar condensation of tertiary-octylphenol and formaldehyde, 2:1 condensation product of tertiary-amylphenol and acetaldehyde, etc.

The preparation of calcium phenates of alkylphenols, alkylphenol sulfides, and alkylphenol-aldehyde condensation products is well known as shown, e.g., by US. Patents Nos. 2,197,833; 2,228,654; 2,228,661; 2,362,289; 2,250,188; 2,280,419; 2,331,448; and 2,252,663. In general, such phenate preparation involves contacting the selected phenolic material with a slight stoichiometric excess of a calcium base such as calcium oxide or hydroxide, calcium methoxide or ethoxide, or calcium carbide at a temperature from about 50 C. to about 200 C. for 0.25- hours. Solvents such as mineral oil, benzene, toluene, and alcohols may be employed to facilitate the reaction, if desired. In some instances, the calcium phenate may be prepared by metathesis of the sodium phenate with a calcium salt such as calcium chloride,

calcium nitrate, etc.

Especially useful as component B herein are the calcium phenates of alkylphenol-aldehyde condensation products such as the condensation product of formaldehyde with monoalkyl mononuclear phenol in which the alkyl substituent contains from about 3 to about 150 and more often from about 4 to about 50 carbon atoms. In lieu of formaldehyde, other lower aldehydes containing from 2 to about 10 carbon atoms such as acetaldehyde, propionaldehyde, butyraldehyde, valeraldehyde, 2- rnethyl-butanal-4, furfural, benzaldehyde, etc., may be employed, although formaldehyde is preferred by reason of its low cost, availability, and reactivity. The calcium phenates of alkylphenol-aldehyde condensation products may be prepared by any one of several known methods such as, e.g., (a) condensation of the alkylphenol and aldehyde in a mole ratio from about 4:1 to about 1:4 for 0.5- hours at 50200 C. in the presence of a small amount, generally 0.5-5 percent, of a basic or acidic catalyst such as aqueous ammonia or hydrochloric acid, followed by conversion of the resulting condensation product to the calcium phenate, (b) preparing and heating for 0.5-15 hours at 50200 C. a mixture of a calcium base such as calcium oxide or hydroxide with an alkylphenol and an aldehyde, in which method the calcium base acts as a catalyst for the condensation reaction and supplies the calcium required for the phenate formation, or (c) heating a mixture of an alkylphenol and acalcium base for 0.5-15 hours at 50200 C. to prepare the calcium phenate and then condensing the latter intermediate with an aldehyde for an additional 0.5-5 hours at 50200 C.

The following examples are presented to illustrate specific oil-soluble calcium phenates useful as component B herein. The low viscosity mineral oil, where used, is a neutral oil having a viscosity of -110 Saybolt seconds at 100 F.

Example 12 2250 parts of mineral oil, 960 parts (5 moles) of heptylphenol, and 50 parts of water are introduced into a reaction vessel and stirred at 25 C. The mixture is heated to 40 C. and 7 parts of calcium hydroxide and 231 parts (7 moles) of 91 percent assay paraformaldehyde is added over a period of 1 hour. The whole is heated to 80 C. and 200 additional parts of calcium hydroxide (making a total of 207 parts or 5 moles) is added over a period of 1 hour at 8090 C. The whole is heated to 150 C. and maintained at that temperature for 12 hours while nitrogen is blown through the mixture to assist in the removal of water. If foaming is encountered, a few drops of polymerized dimethyl silicone foam inhibitor may be added to control the foaming. The reaction mass is then filtered for purposes of purification. The filtrate, a 33.6 percent oil solution of the desired calcium phenate of heptylphenol-formaldehyde condensation product, is found to contain 7.56 percent sulfate ash.

Example 13 1308 grams (3 equivalents) of polyisobutene-substituted phenol in which the polyisobutene substituent contains an average of 22 carbon atoms, 608 grams of mineral oil, 30 grams of water, and 122 grams (3.3 equivalents) of calcium hydroxide are introduced into a reaction vessel and stirred for 0.5 hour at 20 C. grams (4.5 equivalents) of paraformaldehyle is then added and a slight temperature rise is noted due to an exothermic reaction. The whole is then stirred for 1 hour at 100 C. and heated to C. to remove added water and water of reaction. The reaction mass is then filtered for purposes of purification. The filtrate, a 70 percent oil solution of the desired calcium phenate of polyisobutene-substituted phenolformaldehyde condensation product, is found to contain 7.75 percent sulfate ash.

Example 14 915 grams (3 equivalents) of C alkyl substituted phenol, 1000 grams of mineral oil, 30 grams of water, and 122 grams (3.3 equivalents) of calcium hydroxide is introduced into a reaction vessel and stirred. Paraformaldehyde (135 grams, 4.5 equivalents) is added; an exothermic reaction causes the temperature to rise to 35 C. The whole is then heated for 1.5 hours at 98 C. and dried by heating to ISO-160 C. The crude product is filtered for purposes of purification. The filtrate, a 51 percent oil solution of the desired calcium phenate of C alkyl substituted phenol-formaldehyde condensation product, is found to contain 8.64 percent sulfate ash.

Example 15 20 grams (1.0 equivalent) of calcium metal is refluxed with 500 ml. of methanol for 2 hours to prepare a methanol solution of calcium methoxide. 460 grams (1.0 equivalent) of polyisobutene-substituted phenol in which the polyisobutene substituent contains an average of 22 carbon atoms and 300 grams of mineral oil are added and the whole is heated to C. to remove methanol. The crude product is filtered for purposes of purification. The filtrate, a 61.5 percent oil solution of the desired oil-soluble calcium phenate, is found to contain 6.84 percent sulfate ash.

Example 16 332 grams (1.0 equivalent) of di-(tertiary-octylphenol) monosulfide, 41 grams (1.1 equivalents) of calcium hydroxide, 206 grams of 2-ethoxy-ethanol-1, and 100 grams of water are introduced into a reaction vessel and stirred for 1 hour at 100-105 C. Thereafter, the whole is heated to 140 C., 266 parts of mineral oil is added, and volatile material is removed at 160 C./ mm. Hg. The residue in the flask is filtered for purposes of purification. The filtrate, a 57 percent oil solution of the desired calcium phenate of di-(tertiary-octylphenol) monosulfide, shows the following analyses:

Sulfate ash, percent 9.98 Sulfur, percent 2.89

Example 17 56 grams (2.0 equivalents) of calcium oxide is added to 400 grams of ethylene glycol at room temperature. An exothermic reaction causes the temperature to rise to 70 C. The whole is then heated to 120 C. and an additional 100 grams of ethylene glycol is added. Thereafter, 940 grams (2.0 equivalents) of a 50% oil solution of a condensation product of tertiary-octylphenol and formaldehyde (prepared by condensing 1 equivalent of paraformaldehyde with 2.5 equivalents of tertiary-octylphenol in oil solution for 2 hours at 100-110 C. in the presence of 3% by weight of .58 percent aqueous ammonium hydroxide) is added, together with 240 grams of mineral oil, and the whole is stirred for 1 hour at l00-l05 C. Ethylene glycol and any Water of reaction are removed by heating the reaction mixture to a temperature of 160 C. at 10 mm. Hg. The residue is filtered for purposes of purification. The filtrate, a 42 percent oil solution of the desired calcium phenate of tertiary-octylphenol-formaldehyde condensation product, is found to contain 10.1 percent sulfate ash.

COMPONENT c This component, the alcohol, may be any one or more of the various available substituted or unsubstituted aliphatic alcohols containing from 1 to about or more carbon atoms, in which alcohols the aliphatic group has an open chain or cyclic structure. In most cases, the alcohol will conform to the formula ROI-I, wherein R is an open aliphatic hydrocarbon radical containing from 1 to 20 carbon atoms. However, in some instances, the alcohol will contain organic and/ or inorganic substituents such as aromatic radicals, homocyclic radicals, heterocyclic radicals, and nitro, ether, ester, sulfide, keto, amino, nitroso, etc., groups.

Examples of alcohols useful as this compenent include methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, n-pentanol-l, n-pentanol-Z, isoamyl alcohol, n-hexanol-l, n-hexanol-Z, 4-methyl-pentanol-2, n-heptanol, primary isooctanol (prepared, for example, by the wellknown Oxo process), 2-ethylhexanol, n-octanol, 3,5,5- trimethyl-hexanol, cyclohexanol, methylcyclohexanol, ethylcyclohexanol, benzyl alcohol, beta-phenathyl alcohol, 2-alphapyridylethanol-1, tetrahydrofurfuryl alcohol, Z-cyclohexylethanol-l, n-decanol, n-undecanol, lauryl alcohol, isododecanol (prepared, for example, by the hydration of triisobutylene), myristyl alcohol, oleyl alcohol, neicosanol, n-tricosanol, n-triacontanol, 2-phenoxyethanol- 1, Z-phenoxyethoxyethanol-l, 6-chloro-n-hexanol-1, 8- nitro-n-octanol-l, 4-aminocyclohexanol, ethylene glycol monooleate, glyceryl dipalmitate, 2-n-butoxyethanol-1, diethylene glycol monoethyl ether, 2-thiobutoxyethanol-1, etc. Of the various available alcohols, a preference is ex pressed for alkanols containing from 1 to about 12 carbon atoms such as methanol, isobutanol, n-hexanol, mixed primary amyl alcohols, primary isooctanol, Z-ethylhexanol, and lauryl alcohol. In lieu of a single alkanol, mixtures of two or more of such alkanols are particularly preferred. Thus, for example, mixtures of methyl, isobutyl,

10 and primary amyl alcohols are especially effective and desirable as this component.

COMPONENT D Component D, the calcium base, is usually a basic inorganic calcium compound such as calcium oxide, calcium hydroxide, calcium sulfide, calcium hydrosulfide, calcium amide, calcium carbide, calcium hydride, calcium peroxide, calcium nitride, and the like. It is also desirable, in some instances, to use a calcium alcoholate such as calcium methoxide, calcium ethoxide, etc., or a calcium alkyl carbonate such as calcium methyl carbonate. It is to be understood that mixtures of two or more of any of the above calcium bases may be employed as component D. Generally, however, this component will be either calcium oxide or calcium hydroxide.

In the ordinary practice of the invention, the carbonated calcium sulfonate complex of metal ratio 1.1-8, calcium phenate, alcohol, and a portion of the selected calcium base, and optionally, a low viscosity mineral oil are introduced into a reaction vessel and stirred at 30- C. Generally, the sulfonate complex is a solution of 20-75 percent by weight of such complex in a low viscosity mineral oil or volatile petroleum hydrocarbon solvent. The ratio of equivalents of sulfonate complex to calcium phenate is within the range from about 20:1 to about 2:1, more often from about 10:1 to 4:1. For the purpose of this specification, one equivalent of a sulfonate complex is that amount which contains one equivalent of sulfonic acid anion. The amount of alcohol or alcohol mixture used should be at least 5 percent and preferably 5 to 100 percent by weight of the sulfonate complex starting material. After the whole is thoroughly mixed, carbon dioxide is introduced for 05-15 hours at 30- 100C. Thereafter, the remainder of the calcium base is added portionwise, each addition thereof being followed by the introduction of further carbon dioxide. The final carbonation operation is carried out until titration of a sample of the reaction mass shows that the base number thereof is less than about 20, preferably 0-10. The alcohol and any water present are then removed by heating the mass at atmospheric or subatmospheric pressure until distillation has substantially ceased. The final, substantially neutral, carbonated calcium sulfonate complex having a metal ratio of at least about 10 is generally purified by filtration or centrifugation, although for some purposes it is possible to use the crude complex. This particular order of process steps, although most convenient, need not be followed. It is only necessary that the mixture of components AD, inclusive, be carbonated until the base number thereof is less than about 50. The portionwise addition of the calcium base and carbon dioxide does, however, facilitate the formation of the complex in that it prevents the development of a highly viscous reaction mass which is difficult to stir and process.

The following examples are presented to illustrate specific modes of carrying out the process of this invention. They are intended for purposes of illustration only and are not to be construed as limiting the scope of the invention, except as the appended claims require. Unless otherwise specified, all parts and percentages are by weight.

Example 18 1595 parts of the carbonated calcium sulfonate complex of Example 1 (1.54 equivalents based on sulfonic acid anion), 167 parts of the calcium phenate of Example 12 (0.19 equivalents), 616 parts of mineral oil, 157 parts of 91 percent assay calcium hydroxide (3.86 equivalents), 288 parts of methanol, 88 parts of isobutanol, and 56 parts of mixed isomeric primary-amyl alcohols (containing about 65% n-amyl, 3% isoamyl, and 32% of 2- rnethyl-1-butyl alcohols) is stirred vigorously at 40C, and 25 parts of carbon dioxide is introduced over a period of 2 hours at 40-50C. Thereafter, 3 additional portions of calcium hydroxide, each amounting to 157 parts, are added and each such addition is followed by the introduction of carbon dioxide as previously illustrated. After the fourth calcium hydroxide addition and carbonation step is completed, the reaction mass is carbonated for an additional hour at 4347C, to reduce the neutralization numer of the whole to 4.0 (basic). The substantially neutral, carbonated reaction mixture is then freed from alcohol and any water of reaction by heating it to 150C. and simultaneously blowing it with nitrogen. The residue in the reaction vessel is filtered for purposes of purification. The filtrate, an oil solution of the desired substantially neutral, carbonated calcium sulfonate complex of high metal ratio, shoWs the following analyses:

Sulfate ash, percent 41.11 Neutralization No. (basic) 0.9 Netal ratio 12.55

Example 19 A product is prepared in the same manner set forth in Example 18, except that 167 parts of the calcium phenate of Example 13 is used as component B.

Example 20 A product is made in the same manner set forth in Example 18, except that 1595 parts of the carbonated calcium sulfonate complex of Example 2 is employed as Component A.

Example 21 A mixture of 1662 parts by weight of the carbonated calcium sulfonate complex of Example 1, 537 parts of mineral oil, 83 parts of the calcium phenate of Example 12, 153 parts of calcium hydroxide, 125 parts of a 61 39 (by weight) mixture of isobutyl and mixed primary amyl alcohols, and 251 parts of methanol is heated to 45C. and blown with carbon dioxide for 1.8 hours. Thereafter, three successive 154-part increments of calcium hydroxide are added, and the mixture is blown with carbon dioxide for three hours after the first two increments and four hours after the final increment. The mixture is then heated to about 250C. and blown with nitrogen to remove water. The crude unfiltered mixture contains 1.8% solids by volume.

One hundred parts of filter aid material is added to the mixture which is then filtered. After 5 hours, an additional parts of filter aid is added, and four hours thereafter an additional 16 parts is added. The flow of the mixture through the filter is rapid and filtration is complete 14 hours after it is begun. The total consumption of filter aid is 136 parts.

The product thus obtained contains 0.24% solids by volume, and has a calcium sulfate ash content of 43.37% and a base number of 41.

Example 22 Time, hours: Filter aid, parts The total consumption of filter aid is 178 parts, and the filtration takes 25 hours to go to completion. The product contains 0.30% solids by volume, has a calcium sulfate ash content of 43.26 and a base number of 27.

In comparing the process of this invention (Example 21) with a similar process which does not employ a calcium phenate (Example 22), it will be noted that the use of calcium phenate atfords a product with a lower percent solids, that this product is obtained in a substantially shorter time (especially as regards the time necessary for filtration), and that 24% less filter aid is required for filtration.

The substantially neutral, carbonated calcium sulfonate complexes produced in accordance with the present invention can be employed in lubricants intended for use in the crankcases, cylinders, transmissions, gears, chassis, torque converters, etc. of automotive equivalent, industrial machinery, and marine diesel engines. Other suitable uses for the complexes are in asphalt emulsions, insecticidal compositions, stabilizing agents for plactizers and plastics, paints, rust-inhibiting compositions, slushing oils, pesticides, foaming compositions, cutting oils, metal drawing compositions, flushing oils, textile treatment compositions, tanning compositions, metal cleaning compositions, emulsifying agents, antiseptic cleansing compositions, penetrating oils, hydraulic oils, gum solvent compositions, fat-splitting compositions, bonding agents for ceramics and asbestos, asphalt improving agents, flotation agents, improving agents for hydrocarbon fuels such as gasoline, fuel oil, gas oil, etc. They are also useful as starting materials for the preparation of bodied lubricants or greases. For this purpose, the sulfonate complex is gelled by heating it with water or an alcohol-water mixture and the gel thus obtained is blended with oil, preferably a mineral oil.

More particularly, the complexes of this invention are adapted for use in lubricants, paints, and plastics, especially halogen-bearing plastics. In these applications, the complex will be employed in the following concentrations based upon the weight of the total composition. For the preparation of lubricants, a minor proportion, generally from about 0.01 to about 40 parts by weight of the complex of this invention per 100 parts of oil will be blended with a major proportion of the lubricating oil base, which base may contain one or more known additives. In some instances, the lubricating oil base may be a water-in-oil emulsion such as is used in the lubrication of low speed marine diesel engines.

The lubricating oil base is generally in mineral oil having a Saybolt viscosity within the range from about seconds at F. to about 250 seconds at 210 F. It can, however, be a synthetic oil such as a polymerized polyisobutene, polymerized cracked paraffin wax dioctyl adipate, dioctyl sebacate, etc., or a naturally-occurring vegetable or animal oil. Known lubricant additives can also be used, as indicated, in combination with the complexes of this invention. Such known additives include, for example, barium, calcium, lead, zinc, and nickel diorgano phosphorodithioates; phosphorus sulfide-treated olefins; sulfurized and sulfur chloride-treated olefins; alkylphenate sulfides and disulfides; amines such as p-aminophenol, N-alkylated phenylene diamines, and anthranilic acid and esters thereof; metal salts of phosphorus pentasulfide-treated polyethylenes, polypropylenes, polyisobutenes, etc.; hindered phenols such as 2,o-di-tertiary-butyl-4-methylphenol and 4,4-methylene-bis-(2,6-ditertiary butylphenol); organoboron compounds such as borate esters and boric acidtreated amines, amides, and imides; phosphites and phosphates such as di-(4-methyl-2-pentyl) phosphite, dioleyl phosphite, tricresyl phosphate, etc.; foam-inhibiting silicones such as polymerized dimethyl silicones; pour depressants such as wax-alkylated naphthalene, polymerized acrylate and/or methacrylate esters, etc.; oiliness agents such as lard oil, oleic acid, oleic acid amide, glyceryl dioleate, etc.; viscosity index improvers such as polymerized isobutenes, polymerized acrylate and/or methacrylate esters, etc.; extreme pressure agents such as substituted an unsubstituted hydrocarbon sulfides and polysulfides, halogenated aliphatic and cycloaliphatic compounds such as chlorinated parafiin waxes containing 20- 75 percent of chlorine, chlorinated eicosane containing 40-80 percent of chlorine, chlorinated cyclohexane containing 20-7O percent of chlorine, and sulfurized esters such as sulfurized methyl oleate, sulfurized glyceryl trioleate, sulfurized sperm oil, etc.; ashless dispersants such as vinyl pyrrolidone-alkyl acrylate or methacrylate copolymers, vinyl pyridine-alkyl acrylate or methacrylate copolymers, and reaction products of polyisobutene-substituted succinic anhydride with alkylene amines and, optionally, boron-containing compounds, in which reaction products the polyisobutene substituent contains at least about 50 carbon atoms; dithiocarbamic acid esters and salts; xanthic acid esters and salts; and other known lubricant additives.

Especially useful in combination with the sulfonate complexes of this invention in lubricants are minor proportions, generally from about 0.05 to about 8 percent by Weight based on the total lubricant, of zinc dihydrocarbyl phosphorodithioates, phosphorus :pentasulfidetreated terpenes, or alkaline earth metal alkylphenate sulfides.

To illustrate better the wide variety of uses to which the substantially neutral, carbonated calcium sulfonate complexes of this invention are adapted, the following specific examples are presented.

1 1 mole of P285 and 4 moles of turpentine heated for 4 hours at 140 C.

Use in halogen-bearing plastics:

Polyvinyl chloride (55% chlorine) 70.0

Dioctyl phthalate 28.75

Product of Example 18 1.25 Use in paint:

Rutile-base house paint 97.0

Product of Example 21 3.0

What is claimed is: 1. A process for preparing a substantially neutral, carbonated calcium sulfonate complex having a metal ratio of at least about 10 which comprises preparing and mixing a mass in which, at C., at least 50 percent of the components are in the liquid state, and in which mass the active components consist of:

(A) a carbonated calcium sulfonate complex having a metal ratio of from about 1.1 to about 8.0;

(B) an oil-soluble calcium phenate;

the ratio of equivalents of A:B being in the range from about 20:1 to about 2:1;

(C) an aliphatic monohydric alcohol having from 1 to about 20 carbon atoms, in an amount of at least 5 percent by weight of A;

(D) a calcium base, in an amount such that there is present in the mass a total of at least about 10 equivalents of calcium per equivalent of A;

and then treating the mass With carbon dioxide until the base number thereof is less than about 50 and heating it to drive off substantially all the alcohol and any water present.

2. A process in accordance with claim 1 wherein component A is a carbonated calcium petroleum sulfonate complex.

3. A process in accordance with claim 1 wherein component A is a carbonated calcium mahogany sulfonate complex.

4. A process in accordance with claim 1 wherein component A is a carbonated calcium alkaryl sulfonate complex.

5. A process in accordance with claim 1 wherein component A is a carbonated calcium tridecyl benzene bottoms sulfonate complex.

6. A process in accordance with claim 1 wherein component B is a calcium phenate of an alkylphenol-aldehyde condensation product.

7. A process in accordance with claim 1 wherein component B is a calcium phenate of a heptylphenol-formaldehyde condensation product.

8. A process in accordance with claim 1 wherein component C is an alkanol containing from 1 to about 12 carbon atoms.

9. A process in accordance with claim 1 wherein component C is a mixture of methyl, isobutyl, and primary amyl alcohols.

10. A process in accordance with claim 1 wherein component D is calcium hydroxide.

References Cited UNITED STATES PATENTS 2,616,924 11/1952 Asseff et al 252-33 X 2,695,910 11/1954- Asself et al 25233 X 3,027,325 3/ 1962 McMillen et al. 25233 3,172,855 3/1965 Rogers et al. 25233 X 3,312,618 4/1967 Le Suer et al. 25233 DANIEL E. WYMAN, Primary Examiner. PATRICK P. GARVIN, Examiner. 

1. A PROCESS FOR PREPARING A SUBSTANTIALLY NEUTRAL, CARBONATED CALCIUM SULFONATE COMPLEX HAVING A METAL RATIO OF AT LEAST ABOUT 10 WHICH COMPRISES PREPARING AND MIXING A MASS IN WHICH, AT 50*C., AT LEAST 20 PERCENT OF THE COMPONENTS ARE IN THE LIQUID STATE, AND IN WHICH MASS THE ACTIVE COMPONENTS CONSIST OF: (A) A CARBONATED CALCIUM SULFONATE COMPLEX HAVING A METAL RATIO OF FROM ABOUT 1.1 TO ABOUT 2.0; (B) AN OIL-SOLUBLE CALCIUM PHENATE; THE RATIO OF EQUIVALENTS OF A:B BEING IN THE RANGE FROM ABOUT 20:1 TO ABOUT 2:1; (C) AN ALIPHATIC MONOHYDRIC ALCOHOL HAVING FROM 1 TO ABOUT 20 CARBON ATOMS, IN AM AMOUNT OF AT LEAST 5 PERCENT BY WEIGHT OF A; (D) A CALCIUM BASE, IN AN AMOUNT SUCH THAT THERE IS PRESENT IN THE MASS A TOTAL OF AT LEAST ABOUT 10 EQUIVALENTS OF CALCIUM PER EQUIVALENT OF A; AND THEN TREATING THE MASS WITH CARBON DIOXIDE UNTIL THE BASE NUMBER THEREOF IS LESS THAN ABOUT 50 AND HEATING IT TO DRIVE OFF SUBSTANTIALLY ALL THE ALCOHOL AND ANY WATER PRESENT. 